unusual fuel tank leak issue - Toyota Yaris Forums

b1gw0mp66 · 10-01-2023, 01:02 PM

Hello! First time posting here. Have an issue i’ve never seen before and really can’t find much info anywhere about. Am finding that whenever i fill my ‘08 Yaris up to full, gas leaks out from under that red plastic ring where the filler neck attaches to the tank. Quite a lot gushes out, seemingly until the extra gas in the filler neck is emptied out. If I don’t fill it to full I don’t seem to have any leaks whatsoever. That red ring doesn’t seem to have any visible cracks but it does look somewhat warped at the bottom (know the pic isn’t too hi-res to demonstrate). In my research, this does not appear to be a part you can simply remove/replace, but may be mistaken. Seems to just be built into the gas tank. Realize the only solution may be to replace the whole gas tank, but just want to see if there’s any possible way to repair/seal/replace this. Any input is appreciated, thanks!!

Matthew

WeeYari · 10-01-2023, 03:05 PM

Are you first owner? What the hell is a band clamp doing in there? No car rolls off the assembly line using band clamps.

b1gw0mp66 · 10-01-2023, 03:57 PM

definitely not the first owner. figured something seemed fishy there.

BLH · 10-02-2023, 06:37 AM

You may want to do a web search.
For a 2008 fuel system or fuel pipe.
I found a few Toyota part vendors online. Some had diagrams of the parts involved and a part number. That would at least give you an idea to how it is assembled and what parts can be found individually.

I looked at some videos on replacing the metal fuel tube from the filler door to the tank. The tank end does have a rubber piece between the tank inlet and the metal filler tube. There are the clamps you are showing in your photo. So it does look like that style clamp is used on a 2008 and many other cars.

BLH · 10-03-2023, 06:09 AM

My 2007 Yaris Maintenance Manual.
Shows Fuel Tank Filler Pipe Sub-assembly Lower. To connect it to the top of the tank inlet. Tighten the clamp. The rubber piece has a clamp on it and I imagine is designed to be exposed to gasoline.

WeeYari · 10-03-2023, 11:27 AM

I'll be damned. Just took a look at mine and there it is. A band clamp. Surprises me that one is used in such a high corrosion prone area.
First step, remove and replace with a new clamp.

BLH · 10-03-2023, 03:59 PM

Videos I saw seem to agree.
Clamp is in a corrosion zone.
Hard to remove due to the corrosion.
The pipe is also known to corrode.
I would also expect a Cheek Engine Light and codes. If the evaporation system tests detected any leaks.
My 2007 runs the test around six hours after turning off the car. Sometimes you can hear the test pump running the test.

10-01-2023, 03:05 PM	#2
WeeYari View User's Garage Drives: 06 Polar White 5dr, 13 Soul 4u Join Date: Oct 2008 Location: Georgetown, Ontario, Canada Posts: 5,740	Are you first owner? What the hell is a band clamp doing in there? No car rolls off the assembly line using band clamps. __________________

10-02-2023, 06:37 AM	#4
BLH Drives: 2007 Yaris Sedan Join Date: Apr 2009 Location: CT Posts: 271	You may want to do a web search. For a 2008 fuel system or fuel pipe. I found a few Toyota part vendors online. Some had diagrams of the parts involved and a part number. That would at least give you an idea to how it is assembled and what parts can be found individually. I looked at some videos on replacing the metal fuel tube from the filler door to the tank. The tank end does have a rubber piece between the tank inlet and the metal filler tube. There are the clamps you are showing in your photo. So it does look like that style clamp is used on a 2008 and many other cars. Last edited by BLH; 10-02-2023 at 08:22 AM. Reason: Add Information.

10-03-2023, 06:09 AM	#5
BLH Drives: 2007 Yaris Sedan Join Date: Apr 2009 Location: CT Posts: 271	My 2007 Yaris Maintenance Manual. Shows Fuel Tank Filler Pipe Sub-assembly Lower. To connect it to the top of the tank inlet. Tighten the clamp. The rubber piece has a clamp on it and I imagine is designed to be exposed to gasoline. Last edited by BLH; 10-03-2023 at 06:33 AM. Reason: Fix a statement

10-03-2023, 11:27 AM	#6
WeeYari View User's Garage Drives: 06 Polar White 5dr, 13 Soul 4u Join Date: Oct 2008 Location: Georgetown, Ontario, Canada Posts: 5,740	I'll be damned. Just took a look at mine and there it is. A band clamp. Surprises me that one is used in such a high corrosion prone area. First step, remove and replace with a new clamp. __________________

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10-01-2023, 03:57 PM	#3
b1gw0mp66 Drives: ‘08 2dr hatch 5spd Join Date: Oct 2023 Location: Oregon Posts: 2	definitely not the first owner. figured something seemed fishy there.

10-03-2023, 03:59 PM	#7
BLH Drives: 2007 Yaris Sedan Join Date: Apr 2009 Location: CT Posts: 271	Videos I saw seem to agree. Clamp is in a corrosion zone. Hard to remove due to the corrosion. The pipe is also known to corrode. I would also expect a Cheek Engine Light and codes. If the evaporation system tests detected any leaks. My 2007 runs the test around six hours after turning off the car. Sometimes you can hear the test pump running the test.